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Zoltán Dániel, Project Manager – Slovnaft, Bratislava, Slovakia
Linking operational data to business activities enablescollaboration & increases profits
SigmafineReconciliationToolImplementationinSlovnaft Refinery
Presented at the European Petrochemical & Refining Congress, Hamburg, DE – May 22nd – 23rd 2017
Marco Lanteri, Senior Consultant – Pimsoft, Milan, Italy
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1.Introduction
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History
Company
Situation
Solution
Benefits
Introduction• Winthechallengeofproductionaccountingforacomplexsite• Leveragedataqualityintermsof:• Dataconsistency• Dataaccessibility• Dataauditability
• Integrateacompletedataworkflowfromthefielduptotheenterpriselevel
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1.History
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FromthePasttothePresentApollo Refinery 1895 – 1963 (Capacity 30- 40 kt)
Slovnaft Refinery 1957-present days (Current capacity 6100 kt)
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BratislavaSlovnaft Refinery
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2.CompanyOverview
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Bratislava6,1Mt
Schwechat9,6Mt
Ingolstadt12Mt
Vohburg5Mt Burghausen
3,4Mt
Leuna10,7Mt
Schwedt10,5Mt
Litvinov5,2Mt
Kralupy3Mt
Rijeka4,5Mt
Sisak2,3Mt
BosanskiBrod2Mt
NoviSad2,6Mt
Pancevo4,8Mt
PetromPitesti3,5Mt
Lukoil3,5MtPetromPloiesti4,5Mt
RafoOnesti3,5Mt
Drogobich3,8Mt
PKNPlock13,5Mt
Százhalombatta8,1Mt
Mozyr15,5Mt
LOTOS6,2Mt
MantovaLogistichubt
radius 500km
Membersince2000
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Austria
Slovenia
Croatia
Bosnia
Ukraine
Pol&
Czech Rep
Hungary
Crude Oil Pipeline
Friendshippipeline
ADRIA
BratislavaRefinery
SlovakRep.
• REB– RussianExportBlend• SourcedfromRussiavia
Druzhba pipeline(a.k.a.FriendshipPipeline)
Since 1962
Since 2015
SupplySituation
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Facts&figures*
NelsonC.I.
2016Production
*Slovnaft AnnualReport2016&previousyears
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3.Context&Situation
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A10Year Journey…• 2007:Startimplementationofreconciliationthe GroupSolution
• Usestandardtool• Implementationinall sites ofMOLGroup
• Triedtoimplement3timesunsuccesfully:• 2008:Didnotfulfilledtheidentificationofsourcesoflosses• 2009-2012:FocusonDCSimprovements (balancing calculation,lossmanagement &reduction) distractedresources&prevented projectcompletion
• 2012-2014:furtherimplementation notfulfilled:• Autumn2012: Refinery&Petchemmerged intoSNRefinery, causing lackofinternalHumanResources
• May2014: Projectstops duetostartofnewERPsystem,preventing workonintegration
• Until this implementation it was not really aproject,there were otherpriorities,not good planning andtiming (collisions)
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Existing Systems notaligned with thenewbusinessstrategy• Lowperformanceindataentry&limitedanalysiscapabilities
• Onlyonepersoncandobalancingatagiven time• Lotsofmanualdataentries,lotofverificationdaily• Nodiagnostictoolnor graphicalvisualisation
• Poordataquality• Constantproperties (e.g.density)forproduct measurement• Inventory& lossesarefixed
• Limiteddataaccessibility• Nodirect connectionwithplant historian• Informationavailableonlyindatasheets• Nopublishing viaaRefineryInformationSystem
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4.Project&Solution
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Production accountingis…
... the business process of measuring, validating &publishing flows & inventories occurring into, within &out of the plant & the refinery
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Projectobjective
Applysetofunifiedtools &practices tomanageintegratedoperationsbasedonrelevant& timelyinformation&incompliancewith theMOLGroup
guidelines&integratedbusinessprocesses
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FiscalMovements
MovementDeclaration
SigmafineDataValidation&Reconciliation
Anintegratedinformationworkflowfromprocesstoenterpriselevel
WebReports
EnterpriselevelPIHistorian
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CollaborativeAccountingenvironment
MovementOperators
PlantAreas
Accountants
Environment
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Empoweraccountingwithdatascience• Solvabilityanalysisofthenetwork• Statisticaltestsassociatedto• Measurementcorrection• Imbalancecorrection
• Dataqualityindicatorson• Measureddata• Reconcileddata• Overallmodel
• Accountantcanfocusonbadrankingunits&worstmeters
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Turnkeysolutionforasuccessfulimplementation
• CloseteamworkbetweenSlovnaft &Pimsoft• Topmanagementinvolvementfromthevery beginning• Deeppreliminary analysisdonebySuppliertoclearlyidentifyscope&projectrisks• Createasolutionentirelybasedonproductfunctionalitieswithoutcustomdevelopment• Transparencyoninformationamongteams&management
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ProjectTimeline &Status
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DataCollection&Functionaldesign
Implementation/Modelbuilding
2016August
2017July
FATIntegrationTest&Tuning
SAT
2016Nov
2017Mar
2017May
2017June
Go-liveparallel run
Projectclose
FAT- Factory acceptance testSAT– Siteacceptance test
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Implementation Challenges• Complex,integrated refinery&petrochemicalmodel• Many intermediate &finalproductstoragetanks• Complex integration rules with ERP• Many stakeholders• Fitparallel project inMOLPetrochemicals• Many endusers fornewIMMmovement management
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5.Results&Benefits
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RESULTSCHALLENGE SOLUTION
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INITIAL GOAL
Results &Benefits
Dedicatemoretimetodataanalysis&improveaccountingaccuracy,reducingmanhoursspentfordataentry
Makeworkofaccountants&movementoperatorsmoreefficient&coherent
Provideaflexiblesolutionthatallowseasydeclaringofmovements&fullgraphicalinterface&statisticaldiagnostics
Allowmultipleuserstoconnect&workatthesametimethroughaclient-serverarchitecture
Reductionofmanualinputstobedeclared
Divideetimpera approachallowssplittingtheworkloadbyplantareaformovementdeclarationstillkeepingonemodelfortheentirecomplex
Accountantcandetectmoreeasilymajordiscrepancies
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RESULTSCHALLENGE SOLUTION
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INITIAL GOAL
Results &Benefits
Improvelossaccounting
Informer system,productionunits weremodeledasfixed,calculatedbyplanningstandards,mainlyasaportionoffeed;process units andtheir losses were treated asseparate«islands»
Basedondesign&processknowledge,losses(flares,technicallossesatunitlevel,stoichiometrical losses)havebeenintegratedinone,fullyconnected,reconciliationmodel
Lossesarenowaccountedwithabetterdetail&visibilityatunitlevel.
Futureexpectationistoreduceevenfurthertheuncertaintyinlossaccounting
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RESULTSCHALLENGE SOLUTION
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INITIAL GOAL
Results &Benefits
Datavisibleatdifferentcompanylevels,withfullcontroloftheworkflow
Manydifferentdatasource&dataconsumersneedtobepartofthesamepicture¬segregatedinseparateboxes
Sigmafinesolutiontogetherwithitsmovementmanagement&IntegrationFrameworkallowednativeconnectiontothehistorian,processfiscalmovement,historicizereconciledsolution,generatereports&ERPmovements
Alltheproductionaccountingworkflowisnowmanagedthroughonesingleproduct
Dataarevisible,accessible&auditable
Thereisnomoresegregationbetweenprocess&enterpriselevels
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Conclusion
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MeetingbusinessstrategythroughacooperativeanddataqualitydrivenProductionAccounting• One unified environment to• Improve (productions, consumptions and losses)reported to business
(operators and accountants) to providebetter inputs for the balance and in datahandling
on data manipulation from the raw value to the officialreported data
of the solution to add / modify assets in the futureaccording to changes in the plant and to
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FittingMOLGroup2030Strategy• ResilientIntegratedBusinessModel• Createanaccountingsolutionflexible&scalableothertime
• High-Quality/Low-costAssetBase• Leveragequalityofalreadyexistingassetsthroughacomprehensivemodelofrefinery&petrochemicalsite
• Systematicefficiency• Decreasetheneedofmanualinputs&reducehumanfactorbyimplementingasingledataworkflow
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